Quality control
Quality
The word quality does not mean the quality of
manufactured product only. It may refer to the
quality of the process (i.e., men, material, and
machines) and even that of management.
defined as Quality of product as the degree in which
it fulfills the requirement of the customer. It is not
absolute but it judged or realized by comparing it
with some standards.
Crosby defined as Quality is conformance to
requirement or specifications.
Juran defined as Quality is fitness for use.
Quality continue
The Quality of a product or service is the fitness of
that product or service for meeting or exceeding its
intended use as required by the customer.
Control
The process through which the standards are established
and met with standards is called control. This process
consists of observing our activity performance, comparing
the performance with some standard and then taking action
if the observed performance is significantly too different
from the standards.
Control continue.
The control process involves a universal sequence of
steps as follows:
1. Choose the control object
2. Choose a unit of measure
3. Set the standard value
4. Choose a sensing device which can measure
5. Measure actual performance
6. Interpret the difference between actual and
standard
7. Taking action.
Fundamental Factors Affecting Quality
The nine fundamental factors (9 Ms), which are
affecting the quality of products and services, are:
markets,
money,
management,
men,
motivation,
materials,
machines and mechanization.
modern information methods and
mounting product requirements.
Fundamental Factors Affecting Quality
1. Market: Because of technology advancement, we
could see many new products to satisfy customer wants. At
the same time, the customer wants are also changing
dynamically.
2. Money: The increased global competition
necessitates huge outlays for new equipment's and process.
This should be rewarded by improved productivity. This is
possible by minimizing quality costs associated with the
maintenance and improvements of quality level.
3. Management: Because of the increased complex
structure of business organization, the quality related
responsibilities lie with persons at different levels in the
organization.
Fundamental Factors Affecting Quality
4. Men: The rapid growth in technical knowledge
leads to development of human resource with different
specialization.
5. Motivation: If we fix the responsibility of
achieving quality with each individual in the organization
with proper motivation techniques, there will not be any
problem in producing the designed quality products.
6. Materials: Selection of proper materials to meet
the desired tolerance limit is also an important
consideration. Quality attributes like, surface finish,
strength, diameter etc., can be obtained by proper selection
of material.
Fundamental Factors Affecting Quality
7. Machines and mechanization: In order to
have quality products which will lead to higher productivity
of any organization, we need to use advanced machines and
mechanize various operations.
8. Modern information methods: The modern
information methods help in storing and retrieving needed
data for manufacturing, marketing and servicing.
9. Mounting product requirements: Product
diversification to meet customers taste leads to complexity
in design, manufacturing and quality standards. Hence,
companies should plan adequate system to tackle all these
requirements.
Inspection
The inspection and test unit is responsible for
appraising the quality of incoming raw materials and
components as well as the quality of the manufactured
product or service
It checks the components at various stages with
reference to certain predetermined factors and
detecting and sorting out the faulty or defective items.
Purpose of Inspection
1. To distinguish good lots from bad lots.
2. To distinguish good pieces from bad pieces.
3. To determine if the process is changing.
4. To determine if the process is approaching the
specification limits.
5. To rate quality of product.
6. To rate accuracy of inspectors.
7. To measure the precision (accuracy) of the measuring
instrument.
8. To secure products-design information.
9. To measure process capability.
Types of Inspection
Types of inspection are:
1. Floor inspection
2. Centralized inspection
3. Combined inspection
4. Functional inspection
5. First piece inspection
6. Pilot piece inspection
7. Final inspection
Types of Inspection cont..
[Link] INSPECTION
In this system, the inspection is performed at the place of
production. It suggests the checking of materials in process at
the machine or in the production time by patrolling
inspectors. These inspectors move from machine to machine
and from one to the other work centers.
Types of Inspection cont..
2. CENTRALISED INSPECTION
Inspection is carried in a central place with all testing
equipment, sensitive equipment is housed in air-conditioned
area. Samples are brought to the inspection floor for
checking. Centralized inspection may locate in one or more
places in the manufacturing industry.
Types of Inspection cont..
3. COMBINED INSPECTION
Combination of two methods whatever may be the method of
inspection, whether floor or central.
Types of Inspection cont..
4. FUNCTIONAL INSPECTION
This system only checks for the main function, the product is
expected to perform. Thus an electrical motor can be checked
for the specified speed and load characteristics. This is also
called assembly inspection.
Types of Inspection cont..
5. FIRST PIECE OR FIRST-OFF INSPECTIONS
First piece of the shift or lot is inspected. This is particularly
used where automatic machines are employed. Any
discrepancy from the operator as machine tool can be
checked to see that the product is within in control limits.
Types of Inspection cont..
6. PILOT PIECE INSPECTION
This is done immediately after new design or product is
developed. This is suitable for mass production and products
involving large number of components such as automobiles
airplanes etc.,
Types of Inspection cont..
7. FINAL INSPECTION
This is also similar to functional or assembly inspection. This
inspection is done only after completion of work. This is
widely employed in process industries where there is not
possible such as, electroplating or anodizing products. This is
done in conjunction with incoming material inspection.
Methods of Inspection
1. 100% inspection
This type will involve careful inspection in detail of
quality at each strategic point or stage of manufacture
where the test is involved is non-destructive and every
piece is separately inspected. Example: Jet engines,
aircraft, medical and scientific equipment.
2. Sampling inspection
In this method randomly selected samples are
inspected. Samples taken from different patches of
products are representatives. If the sample proves
defective, the entire concerned is to be rejected or
recovered. Example: Electrical bulbs, radio bulbs, washing
machine etc.
QUALITY CONTROL
Quality Control (QC) may be defined as a system that is
used to maintain a desired level of quality in a product or
service. It is a systematic control of various factors that
affect the quality of the product. It depends on materials,
tools, machines, type of labor, working conditions etc.
QC is a broad term, it involves inspection at particular
stage but mere inspection does not mean QC.
defined as The operational techniques and the activities
which sustain a quality of product or service that will
satisfy given needs; also the use of such techniques and
activities.
Benefits of Quality Control
Improving the quality of products and services.
Increasing
the productivity of manufacturing
processes, commercial business, corporations.
Reducing manufacturing and corporate costs.
Determining and improving the marketability of
products and services.
Reducing consumer prices of products and services.
Improving and/or assuring on time deliveries and
availability.
Assisting in the management of an enterprise.
Seven Tools for Quality Control
These tools are effect on quality improvement. The
seven quality control tools are:
1. Pareto charts
2. Check sheets
3. Cause and effect diagram
4. Scatter diagrams
5. Histogram
6. Graphs or flow charts
7. Control charts
Seven Tools for Quality Control cont
1. Pareto charts
The Pareto analysis can be used to identify the
problem in a number of forms.
(a) Analysis of losses by material (number or past number).
(b) Analysis of losses by process i.e., classification of
defects
or lot rejections in terms of the process.
(c) Analysis of losses by product family.
(d) Analysis by supplier across the entire spectrum (range) of
purchases.
(e) Analysis by cost of the parts.
(f) Analysis by failure mode.
Seven Tools for Quality Control cont
Example: The Fig. 6.1 shows a Pareto chart of
reasons for poor quality. Poor design will be the major
reason, as indicated by 64%. Thus, this is the problem
that the manufacturing unit should address first.
A Poor Design
B Defective Parts
C Operator Error
D Wrong Dimensions (Sizes)
E Surface Abrasion (Scratch)
F Machine Calibrations (Standardizations)
G Defective Material
Seven Tools for Quality Control cont
2. CHECK SHEETS
Check sheets facilitate systematic record keeping or data
collection observations are recorded as they happen which
reveals patterns or trends.
Data collection through the use of a checklist is often the
first step in analysis of quality problem.
A checklist is a form used to record the frequency of
occurrence of certain product or service characteristics
related to quality.
The characteristics may be measurable on a continuous
scale such as weight, diameter, time or length.
Seven Tools for Quality Control cont
Seven Tools for Quality Control cont
3. CAUSE AND EFFECT DIAGRAM
It is sometimes called as Fish-bone diagram.
It is first developed by Kaorv Ishikawa in 1943 and is
sometimes called as Ishikawa diagram.
The diameter helps the management trace customer
complaints directly to the operations involved.
Seven Tools for Quality Control cont
Seven Tools for Quality Control cont
4. SCATTER DIAGRAM (SCATTER PLOTS)
It often indicates the relationship between two
variables.
They are often used as follow-ups to a cause and
effect analysis to determine whether a stated cause
truly does impact the quality characteristics.
Seven Tools for Quality Control cont
Example: The above figure plots advertising expenditure
against company sales and indicates a strong positive
relationship between the two variables. As the level of
advertising expenditure increases sales tend to increase.
Seven Tools for Quality Control cont.
5. HISTOGRAM (OR) BAR CHARTS
It displays the large amounts of data that are difficult to
interpret in their raw form.
A histogram summarizes data measured on a continuous
scale showing the frequency distribution of some quality
characteristics (in statistical terms the central tendency
and the dispersion of the data).
Often the mean of the data is indicated on the histogram.
A bar chart is a series of bare representing the frequency of
occurrence of data characteristics, the bar height
indicates the number of times a particular quality
characteristic was observed.
Seven Tools for Quality Control cont.
Seven Tools for Quality Control cont
6. FLOW CHARTS (OR) GRAPHS
It shows the sequence of events in a process. They are used
for manufacturing and service operations.
Flow charts are often used to diagram operational
procedures to simplify the system. They can identify
bottlenecks (blocks) , redundant (jobless) steps and nonvalue added activities. A realistic flow chart can be
constructed by using the knowledge of the person who are
directly involved in the particular process.
The flow chart can be identifies where delays can occur.
Seven Tools for Quality Control cont
Seven Tools for Quality Control cont
7. CONTROL CHARTS
It distinguish special causes of variations from
common causes of variation.
They are used to monitor and control process on an
ongoing basis.
A typical control chart plots a selected quality
characteristic found from sub-group of observations as
a function of sample number.
Characteristics such as sample average, sample
range and sample proportion of non-conforming units
are plotted.
Seven Tools for Quality Control cont
TOTAL QUALITY MANAGEMENT
Now-a-days,
customers demand products/services with
greater durability and reliability at the most economic price.
This forces producers to strictly follow quality procedures
right from design till shipment and installation of the
products.
So that goal of any competitive industry is to provide a
product or service at the most economical costs, ensuring full
customer satisfaction.
This can be achieved through Total Quality Management
(TQM), because, quality is not a technical function, but a
systemic process extending through out all phases of the
business, e.g., marketing, design, development,
engineering, purchasing, production/operations.
Total Quality Management (TQM)
As per Feigebaum, Total Quality Management is an
effective system of integrating the quality
development, quality maintenance and quality
improvement efforts of various groups in an
organization so as to enable marketing, engineering,
production and service at the most economical levels
which allow for full customer satisfaction.
Benefits of TQM
The benefits of TQM can be classified into the following two categories:
1. Customer satisfaction oriented benefits.
2. Economic improvements oriented benefits.
1. Customer satisfaction oriented benefits: The benefits under this category
are listed below:
(a) Improvement in product quality.
(b) Improvement in product design.
(c) Improvement in production flow.
(d) Improvement in employee morale and quality consciousness.
(e) Improvement of product service.
(f) Improvement in market place acceptance.
2. Economic improvements oriented benefits: The benefits under this
category are as follows:
(a) Reductions in operating costs.
(b) Reductions in operating losses.
(c) Reductions in field service costs.
(d) Reductions in liability exposure.
ISO 9000 SERIES
ISO stands for International Organization for
Standardization. It is an international body, which
consists of representatives from more than 90
countries. The national standard bodies of these
countries are the members of this organization.
ISO 9000 SERIES cont.
ISO 9000 standards expect firms to have a quality
manual that meets ISO guidelines, documents, quality
procedures and job instructions, and verification of
compliance by third-party auditors. ISO 9000 series has
five international standards on quality managements.
They are:
1. ISO 9000 Quality management and Quality assurance
standards
2. ISO 9001 Quality systems: Quality in design
3. ISO 9002 Quality systems: Production and Installation
4. ISO 9003 Quality systems: Final inspection and test
5. ISO 9004 Quality management and systems
Objectives of ISO 9000 Series
Benefits of ISO 9000 Series
ISO 9000 series provides several tangible and intangible
benefits which are listed below:
1. This gives competitive advantage in the global market.
2. Consistency in quality, since ISO helps in detecting non-conformity
early which makes it possible to take corrective action.
3. Documentation of quality procedures adds clarity to quality system.
4. ISO 9000 ensures adequate and regular quality training for all
members of the organization.
5. ISO helps the customers to have cost effective purchase procedure.
6. The customers while making purchases from companies with ISO
certificate need not spend much on inspection and testing. This will
reduce the quality cost and lead-time.
7. This will help in increasing productivity.
8. This will aid to improved morale and involvement of workers.
9. The level of job satisfaction would be more.
ISO 14000 SERIES
The environmental standards of ISO 14000 deal
with how a company manages the environment
inside its facilities and the immediate outside
environment. However, the standards also call for
analysis of the entire life cycle of a product, from
raw material to eventual disposal.
ISO 14000 SERIES cont..
Some of the standards in the ISO 14000 series are:
ISO 14001Specification of Environmental Management
Systems
ISO 14004Guideline Standard
ISO 14010 through ISO 14015Environmental Auditing
and Related Activities
ISO 14020 through ISO 14024Environmental Labeling
ISO
14031 through ISO 14032Environmental
Performance Evaluation
ISO 14040 through ISO 14043Life Cycle Assessment
ISO 14050Terms and Definitions
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